Numerical Investigation of Deposition Characteristics of PLA on an ABS Plate Using a Material Extrusion Process

Abstract

Three-dimensional prototypes and final products are commonly fabricated using the material extrusion (ME) process in additive manufacturing applications. However, these prototypes and products are limited to a single material using the ME process due to technical challenges. Deposition of plastic on another dissimilar plastic substrate requires proper control of printing temperature during an ME process due to differences in melting temperatures of dissimilar plastics. In this paper, deposition of PLA filament on an ABS substrate during an ME process is investigated using finite element analysis. A heat transfer finite element (FE) model for the extrusion process is proposed to estimate the parameters of the ME machine for the formulation of a heat flux model. The effects of printing temperature and the stand-off distance on temperature distributions are investigated using the proposed FE model for the extrusion process. The heat flux model is implemented in a proposed heat transfer FE model of single bead deposition of PLA on an ABS plate. From this FE model of deposition, temperature histories during the ME deposition process are estimated. The results of temperature histories are compared with experiments. Using the calibrated FE model, a proper heating temperature of ABS for deposition of PLA is evaluated.

Experimentation and Numerical Modeling of Peak Temperature in the Weld Joint during Rotary Friction Welding of Dissimilar Plastic Rods

“…The image resolution for the thermal imaging data is about 1440 × 1080 pixels. In general, the melting temperature for PC and ABS is about 155 ± 10 • C and 245 ± 10 • C, respectively [37,38]. Figure 7 shows the relationship between weld joint temperature and FW time for PLA and PLA rods at a rotational speed of 950 rpm.…”

3D-Printed Fiber-Reinforced Polymer Composites by Fused Deposition Modelling (FDM): Fiber Length and Fiber Implementation Techniques

“…The potential of FDM printed fiber reinforced composites formed by other bio-based polymers or bio-degradable biopolymers (as matrix) and natural fiber (as reinforcement) should be explored. Similarly, bioactive particles integration within the FDM can be explored [ 155 , 156 ].There is also a need to develop better numerical models with a focus on: (i) the manufacturing process of printed parts to reduce development costs, optimize the deposition parameters and provide a better scientific understanding of the fiber reinforced FDM process, based on current research in simulation of FDM manufacturing process [ 157 , 158 ]; and (ii) developing models to understand the deformation and failure mechanism of printed parts under mechanical and/or thermal loading conditions [ 32 , 151 , 159 ]. Some of these models can incorporate hardening, pore closure, creep and the plasticity of polymeric materials [ 160 , 161 , 162 ].…”

Thermoforming Characteristics of PLA/TPU Multi-Material Specimens Fabricated with Fused Deposition Modelling under Different Temperatures

“…Fused deposition modelling (FDM) is commonly used for rapid prototyping. This method is based on the extrusion of molten filament as the material which is being dispensed layer by layer through a heated nozzle according to a sliced model [ 1 , 2 ]. Although the product produced by this method is rigid and accurate, the deposition process time is long to create a three-dimensional (3D) object [ 3 ].…”